Safety Link X-Rail Quick start guide

INSTRUCTION: XRAIL-INST-SURFACE-MOUNT REVISION: 2.0
®
Innovative
Fall Protection
SafetyLink
Figure 1
x-Rail
InStallation and Use
Horizontal Rigid anchor line

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1 Warning
⚠ Improper Use, Installation or Maintenance may result in serious injury or death.
⚠ The building or structure for the anchorages should be assessed by an engineer to
ensure that the structure is adequate for X-Rail installation works.
⚠ SafetyLink's Height Safety Systems must only be installed as per our installation
guides, to structures as specified in the installation manual for each product.
⚠ All safety procedures must be complied with in accordance with the current safety
code(s) of practice(s) for working at heights in your region. Ensure safety at all times by
being attached to suitable anchor points and approved safety equipment or approved
scaffolding.
⚠ Installation is to be carried out by, or under the supervision of, a competent person.
⚠ A personal energy absorber or a fall-arrest device with a personal energy absorber
must be used in conjunction with all SafetyLink Anchorages and Lifeline systems.
⚠ Do not carry out any modifications on this system without written permission by
SafetyLink Pty Ltd.
2 Specification
2.1 Description
The SafetyLink X-Rail is a Rigid Anchor Line suitable for use as part of a personal fall protection
system. The X-Rail offers a horizontal Rigid Anchor Line with one or multiple Mobile Anchor
Points for attaching to.
2.2 Standard
The X-Rail Rigid Anchor Line System is compliant with AS/NZS 1891.2, EN795:2012 and PD
CEN/TS 16415:2013.
2.3 User Rating
The X-Rail Rigid Anchor Line is rated for up to 4 users per system and in any span.
2.4 Material Specification
COMPONENT DESCRIPTION
Rail Aluminium 6000 series
Cross Plates Aluminium 6000 series
Joins Aluminium 6000 series
Fasteners Stainless steel 316
End Cap Nylon 66
End Stop Aluminium 6000 series, Rubberised Nylon
Shuttle Aluminium 6000 series, Stainless steel 316, Nylon 66

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2.5 Components
Figure 2
RAIL LENGTH 3M CROSS PLATE RAIL JOIN KIT CONCEALED
XRAIL-TR-102-3M XRAIL-TR-210 XRAIL-TR-005
RAIL END CAP SHUTTLE STOP SHUTTLE
XRAIL-TR-213 XRAIL-TR-006 XRAIL-TR-014
90°CORNER 45°CORNER RAIL JOIN DOWEL
XRAIL-TR-104 XRAIL-TR-107 XRAIL-TR-212
RAIL SCREW DRILL ON-SITE FIXTURE RAIL DRILL BIT
XRAIL-TR-907(OTS) XRAIL-TR-402 XRAIL-TR-401

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3 Installation
3.1 System Design
3.1.1 General
Systems shall be designed to limit free fall, swing fall and maximise fall clearance. Where
possible, systems should be designed to prevent a free fall from occurring.
It is important to consider the location of corners when designing your system to ensure the
rails and corner fastening detail can match the detail in Section 4 of this instruction.
The X-Rail Rigid Anchor Line shall be installed on an angle no greater than 5º.
Figure 3
5˚

3.1.2 Structure Capacity
The supporting structure shall be capable of supporting 15kN in all direction that the system
can be loaded.
⚠ All load cases shall be considered by a trained engineer.
The structures in Figure 4 have been assessed by SafetyLink and are deemed to be acceptable.
⚠ If there is any doubt of the structures suitability, consult a trained engineer.
Figure 4
Type Size Spacing
Steel Purlin C or Z 150mm x
60mm x 1.5mm
Maximum purlin spacing 600mm or rail system to span
a minimum of 5 purlins.
Timber Rafter
and Batten
Rafter F7 or MGP
10 140mm x
45mm, Batten F7
or MGP 10 70mm
x 35mm
Maximum rafter spacing 600mm

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3.1.3 Intermediate Fixing Spacing
Exact intermediate fixing spacings are determined by the roof sheeting. The below are the
maximum allowable distances.
I On a straight section of rail designed for fall arrest, intermediate fixing shall be
installed at a distance not greater than 1m.
II On a straight section of rail designed for abseil, intermediate fixings shall be
installed at a distance not greater than 0.6m.
Figure 5
A
A
Across the Seam In-line with the Seam
A - 1000mm maximum for fall arrest
A - 600mm maximum for abseil
Figure 6
SPAN LENGTH MAXIMUM DEFLECTION (4 PERSONS)
600mm 50mm
1000mm 200mm
3.1.4 Structure Fixings
To prevent the below listed roof profiles from slipping or moving under load, 8mm Tri fold
aluminium rivet shall be installed in to the purlins along the entire length of the rail. One rivet
shall be installed in each pan of the sheeting, either above or below the rail. Rivets shall only
be installed for rails running across the seams of the roof sheet. See Figure 7.
I Klip-Lok 700
II Klip-Lok 700 Hi-Strength
III Klip-Lok 406

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Figure 7
3.2 Fixings
3.2.1 Rivets
All rivets used to connect the rail profile to the roof sheeting, rail profile to the Cross plate or
Cross plate to the roof sheeting shall be; 8mm Tri fold aluminium rivets measuring 27.7mm
long with a grip range of 1.0-9.5mm. Drill size 7.8-8.2mm.
⚠ Rivets installed in to the lap join of the roof sheet shall penetrate both joining roof
sheets.
Figure 8

After installation, the mandrel of the rivet shall visible below the sealing mound. The mandrel
is required to be in contact with the sealing mound to create a waterproof seal. In addition,
the seal of the rivet shall be compressed between the rail surface and the top of the rivet.
Figure 9
Seal Mandrel
Sealing Mound

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3.2.2 Clamps
For certain roof sheet profiles the X-Rail may be installed with the below clamps.
Figure 10
CLAMPS ROOF SHEET INSTALL TORQUE
(MAIN)
INSTALL TORQUE
(SIDE) IF APP
S5 Z KingZip400 40Nm 16Nm
3.3 Fasteners
All X-Rail Fasteners are M10 socket head cap screws. All fasteners shall be tightened to 40Nm
with a 6mm hex wrench.
⚠ All bolt threads must be applied with Loctite 243 thread-locker or equivalent prior to
assembly. (IMPORTANT NOTE: Before applying Loctite 243 use Loctite 7471 primer or
equivalent to activate the surface according to manufacturer’s instructions).
4 System Assembly
4.3.1 System Termination / Shuttle Stop
At the end of a system or at a point where it is necessary to prevent the passage of a shuttle,
a shuttle stop shall be installed. Drill an 11mm diameter hole in the centre of the rail, through
the top surface only. Where the rail terminates an end cap should be fitted.
Figure 11
1
2
STEP 1 STEP 2
COMPLETE SYSTEM TERMINATION AND STOP

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4.3.2 Rail Joins
Each join in the rail shall be fastened with the Rail Joiner as shown in Figure 12. Holes for rail
join fasteners to be made with drill bit XRAIL-TR-401 and drill fixture XRAIL-TR-402.
Figure 12
1
2
1
2
STEP 1 STEP 2
STEP 3 COMPLETE JOIN

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4.3.3 Corner Single Bend or Jogs
Single corners are used to change the direction of the rail without traversing a ridge.
Figure 13
1
2
2
1
STEP 1 STEP 2
2
1
STEP 3 STEP 4
2
1
STEP 5 STEP 6
COMPLETE SINGLE CORNER

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4.3.4 Corner Compound Bend
Compound corners are used to traverse a ridge. These corners are unique to specific
structures and may require further support not shown below. Please contact SafetyLink for
more information.
Figure 14
2
1
2
1
STEP 1 STEP 2
1
2
12
2
STEP 3 STEP 4
STEP 5 COMPLETE

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4.1 Roof Sheet Fixing
4.1.1 Rivet fixing across the seam install method 1
Figure 15
AA
80
MIN
END JOIN
B
A
25
C
25
25
MIN
INTERMEDIATE FIXING CORNER SINGLE
4.1.2 Rivet fixing inline with the seam install method 1
Figure 16
C
25 MIN
C
25 MIN
END JOIN
B
MAX
C
25 MIN
C
25 MIN
A
25
C
25
25
MIN
INTERMEDIATE FIXING CORNER SINGLE

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4.1.3 Rivet fixing across the seam install method 2
Figure 17
AAA
80
MIN
END JOIN
B
A
25
A
25
25
MIN
A
A
A
INTERMEDIATE FIXING CORNER SINGLE
4.1.4 Rivet fixing inline with the seam install method 2
Figure 18
25
MIN
A
A
A
600
25
MIN
A
A
A
END JOIN
B
MAX
CC
25
MIN
25
MIN
A
25
A
25
25
MIN
A
A
A
INTERMEDIATE FIXING CORNER SINGLE

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4.1.5 Clamp fixing across the seam
Figure 19
AA
100
MIN
END JOIN
B
INTERMEDIATE FIXING
Figure 20
Sheeting Fixing A (mm) B (mm) C (mm)
TrimDek Rivets method 1 190.5 Max 1000 381 or 572
SpanDek Rivets method 1 175 Max 1000 350-525
Custom Orb Rivets method 1 229 Max 1000 381-534
Klip-Lok 700 Hi-Strength Rivets method 2 233 Max 1000 467
Klip-Lok Classic 700 Rivets method 2 233 Max 1000 467
Klip-Lok 406 Rivets method 2 203 Max 1000 609
KingSpan 400 Clamps 400 Max 1000 400

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5 Limitations of Use
5.1 Fall Clearance
When planning your fall protection system, it is important to accurately assess all components
of your system in order to avoid injury. Figure 21 provides guidance on how to calculate fall
clearance, (A) represents the deflection Rigid Anchor Line see Figure 6, (B) represents free
fall, energy absorber deployment as well as the estimated D-ring side of the harness (Refer
the manufacturer's information), (SF) represents the recommended safety factor of 1m, (FC)
represents the total allowable fall clearance. For safe use (FC) shall always be greater than
A+B + SF.
Figure 21
A
B
FC
SF
5.2 Swing Fall
Working off centre of a horizontal line or rail may cause a swing fall. See Figure 22. Fall
protection systems shall be setup in such a way to limit swing fall.
⚠ The force of striking an object during a swing fall may result in serious injury or death.
Figure 22

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5.3 Hazards
Use of this equipment in the presence of hazards may cause damage to the equipment and/
or result in the function of the equipment being impeded. These hazards include but are
not limited to; extreme temperature, sharp edges, chemical reagents, electrical conductivity,
abrasion, cutting, climatic exposure and rotating or moving machinery.
5.4 Training
It is essential that all users are trained in the proper inspection, setup and use of this equipment.
It’s the responsibility of the user to ensure they are trained in the correct use of this equipment
and understand the limitations of its use.
⚠ Incorrect use of this equipment may result in serious injury of death.
5.5 Rescue
It is the responsibility of the user of this equipment and their employer to have a suitable
rescue plan and the ability to implement it at any time during setup and use of this equipment.
6 Connections
6.1 Making Connection
Only make compatible connections. Always ensure connectors close and lock correctly before
use. Below and Figure 24 are examples of unsuitable connections;
1 To an anchor or D-ring which has another connector attached.
2 In a position that will apply load to the gate mechanism.
3 By passing the connection through the attachment.
4 Connecting a connector to another connector.
5 Around a structure and back to the lifeline.
6 To an attachment that will limit the function of the gate.
7 To a location that will not load the connector as designed.
6.2 Compatibility of Connections
Connection made to and with this equipment shall be compatible. Connector shall be
compatible shape, size and equivalent rating in order to ensure a compatible connection
is made. Incompatible connections may cause loading of the gate mechanism leading to
unintentional disengagement. See Figure 23. Connectors shall be compliant with EN362 and
auto closing and locking.
⚠ Making incompatible or unsuitable connection may result in unintentional
disengagement of the connector resulting in serious injury or death.

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Figure 23 Figure 24
⚠
⚠
☠
12
1
234
6
7

5





7 Use
7.1 Planning
Before starting work, plan your working at heights and rescue systems by accounting for
all hazards present in the work place and allowing for the available fall clearance. Ensure all
users are fit, healthy and capable of safely operating this equipment as well as implementing
the rescue plan.
7.2 Working Range
The X-Rail Rigid Anchor Line should be used in a 180º arc around the attachment point of the
shuttle along the length of the rail. Operating outside this range may cause connecting devices
to interfere with intermediate or end bracket fixings or result in the gate of the connector
being loaded.
Figure 25




180º
⚠ During use always allow for the required fall clearance, swing fall and hazards present
in the work place.

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7.3 Connection to the X-Rail Shuttle
The X-Rail has one attachment for connecting the users system to the shuttle, see Figure 26.
Connection shall be made with an auto-locking compatible connector.
7.4 Shuttle Lock
To lock the position of the shuttle along the rail for work positioning or abseil purposes turn
the locking bolt clockwise till the shuttle locks on the rail. To release the shuttle turn the
locking bolt counter clockwise till the shuttle is free to move.
Figure 26 Figure 27
⚠ Each shuttle is for a single user. Do not attach multiple users to a single shuttle.
⚠ Do not attach to any other point on the X-Rail Shuttle or Rigid Anchor Line.
⚠ Use of incompatible connectors may lead to forced roll out and unintentional
disconnection.
⚠ Always consult the connecting system manufacturer's instruction to ensure it is
suitable for use with this equipment.
⚠ Only ever operate this equipment within the allowable operation range specified in
this instruction, see Figure 25.
8 Storage, Transport and Maintenance
8.1 Storage and transport
This equipment shall be stored and transported in a cool, dry environment, away from any
hazards and out of direct sunlight.
8.2 Maintenance
8.2.1 The X-Rail system is serviceable only by trained and authorised installers. Contact
SafetyLink to find your nearest available installer. The service interval will be determined by
the condition in which it is used. Harsher conditions will require more frequent servicing. The
equipment may remain in service until it fails an inspection or is involved in a fall.
8.2.2 The X-Rail Shuttle is non serviceable. The equipment may remain in service until it fails
an inspection or is involved in a fall.
⚠ Do not attempt to modify or disassemble this product.

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8.3 Cleaning
The X-Rail Rigid Anchor Line may be cleaned by the end user periodically to increase service
life. After cleaning, the product shall undergo the pre-use inspection.
Rails and System - Clean rail, joiners, brackets fixing and fasteners with a rag and warm
water to remove dirt and grit. A mild detergent may be used to remove grease or oils from
the product.
Shuttle - Clean Shuttle with a rag and warm water to remove dirt and grit. A mild detergent
may be used to remove grease or oils from the product.
⚠ Do not store this product when wet. Allow the product to dry and conduct a pre-use
inspection prior to return the item to service.
9 Inspection
9.1 Before and After Use
The X-Rail Rigid Anchor Line shall be inspected before and after each use by the user.
9.2 Competent Person
A competent person shall inspect the product at least every 12 months.
9.3 Procedure
9.3.1 Rail - inspect the rail for deformation, damage, dents or debris that may affect the
strength of the rail or impede the Shuttle.
9.3.2 Joiners, System stop - inspect all fasteners are present and tight. Inspect the aluminium
for chips, cracks, discolouration, damage to the protective coating, bending or warping.
9.3.3 Corners and Jogs - inspect for deformation, damage, dents or debris that may affect
the strength of the rail or impede the Shuttle. Inspect all the fasteners are present and tight.
9.3.4 Fixings - inspect all fixings are present and tight. Inspect Fixings are free of damage,
debris, cracks, and corrosion.
9.3.5 Shuttle - inspect the housing is free of cracks, damage or deformation. Inspect the
attachment point is free of cracks, damage or deformation. Ensure all screws are present and
not loose. Inspect all the wheels contact the rail and the shuttle moves smoothly over the rail.
Inspect the markings are present and legible.
9.3.6 Fasteners - inspect the fasteners for corrosion, deformation, damage or leaks. Inspect
the rivets (where applicable) are installed in the correct number and location. Inspect the
clamps (where applicable) are torqued correct and installed in the correct number and location
9.3.7 Roof - inspect the roof sheet and structure for corrosion, deformation, damage or leaks
that may affect the strength of the roof.
9.3.8 Label - inspect the system label is present and legible as per Figure 28.

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INSPECTION RECORD
Product Code Date of Manufacture
Serial or Batch No. Date of Install
Inspector Date of Inspection
PROCEDURE INSPECTION USER COMPETENT
PERSON
9.3.1 Rail - inspect the rail for deformation, damage, dents
or debris that may affect the strength of the rail or
impede the Shuttle.
 
Comments:
9.3.2 Joiners, System stop - inspect all fasteners are present
and tight. Inspect the aluminium for chips, cracks,
discolouration, damage to the protective coating,
bending or warping.
 
Comments:
9.3.3 Corners and Jogs - inspect for deformation, damage,
dents or debris that may affect the strength of the rail
or impede the Shuttle. Inspect all the fasteners are
present and tight.
 
Comments:
9.3.4 Fixings - inspect all fixings are present and tight.
Inspect Fixings are free of damage, debris, cracks, and
corrosion.
 
Comments:
9.3.5 Shuttle - inspect the housing is free of cracks, damage
or deformation. Inspect the attachment point is free of
cracks, damage or deformation. Ensure all screws are
present and not loose. Inspect all the wheels contact
the rail and the shuttle moves smoothly over the rail.
Inspect the markings are present and legible.
 
Comments:
9.3.6 Fasteners - inspect the fasteners for corrosion,
deformation, damage or leaks. Inspect the rivets
(where applicable) are installed in the correct number
and location. Inspect the clamps (where applicable)
are torqued correct and installed in the correct number
and location
 
Comments:
9.3.7 Roof - inspect the roof sheet and structure for
corrosion, deformation, damage or leaks that may
affect the strength of the roof.
 
Comments:
9.3.8 Label - inspect the system label is present and legible
as per Figure 28.  
Comments:

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Figure 28
x-rail horizontal rigid
anchor line
NUMBER OF USERS  1x � 2x � 3x � 4x �
SYSTEM USE  Fall Arrest Abseil
INSTALLED DATE __/__/____ (DD/MM/YYYY) INSTALLED BY
STANDARDS EN795:2012/D
CEN/TS 16415:2013
AS/NZS 1891.2:2009
1x
/
ONLY EVER CONNECT 1 USER TO EACH SHUTTLE
Inspection record
1 __/__/____ (DD/MM/YYYY) 6 __/__/____ (DD/MM/YYYY)
2 __/__/____ (DD/MM/YYYY) 7 __/__/____ (DD/MM/YYYY)
3 __/__/____ (DD/MM/YYYY) 8 __/__/____ (DD/MM/YYYY)
4 __/__/____ (DD/MM/YYYY) 9 __/__/____ (DD/MM/YYYY)
5 __/__/____ (DD/MM/YYYY) 10 __/__/____ (DD/MM/YYYY)
SafetyLink Pty Ltd | ABN 83 081 777 371
Phone: [phone] or [phone]
[email protected] | www.safetylink.com
SYSTEM LABEL - XRAIL-TR-WARN